Systems and methods for sorting and collecting enhanced metal-bearing ores of a desired size from metal-bearing ores

ABSTRACT

Disclosed is a system and method for sorting copper-bearing ore to select portions having a target copper content. The system includes an analysis and selection station including first magnetic resonance analyzer measuring the copper content of input ore and a controlled diverter to divert portions of the input ore to a collection path when the copper content meets or exceeds a predetermined cut-off value. The predetermined cut-off is adjusted by a controller in response to the first magnetic resonance analyzer. A second magnetic resonance analyzer measures the copper content of the ore in a product path. That measurement is fed back to the controller to fine tune the adjusted cut-off value above, up or down, to optimize the yield of ore having the targeted copper content. The system may include a station for sizing the input ore, a station for sizing the output ore, and a station for sizing waste produced by the system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This PCT application is a Continuation-In-Part of, and takes the benefitunder 35 U.S.C. § 120 of, application Ser. No. 16/582,104 filed on Sep.25, 2019, entitled Systems and Methods for Sorting and CollectingEnhanced Grade Metal-Bearing Ores from Metal Bearing Ores, which in turntakes the benefit under 35 U.S.C. § 119(e) of Provisional ApplicationSer. No. 62/771,280 filed on Nov. 26, 2018, entitled Systems and Methodsfor Sorting and Collecting Enhanced Grade Metal-Bearing Ores from MetalBearing Ores, the disclosures of both of those applications beingspecifically incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates generally to mining and more particularly tosystems and methods for sorting and collecting a predetermined grademetal-bearing ore, e.g., copper-bearing ore, from metal-bearing ore.

SPECIFICATION Background of the Invention

The mining of metals, such as copper, from metal-bearing ore typicallyentails initially taking core samples of an orebody to determine thepotential grades of the ore therein. Porphyry copper orebodies aretypically very large (hundreds of millions of tons) but lowgrade—typically less than 1.0% copper content. They may contain othervaluable metals—gold, silver, molybdenum and magnetite as well asdeleterious minerals containing arsenic and sulphur. The copper ore maybe mined by open pit or underground methods depending on the shape andextent of the orebody. The orebodies were formed by a process of magmaflow and then the metallic minerals were deposited from flow ofhydrothermal mineralizing fluids containing metallic compounds along anetwork of veinlets and cracks through the cooling magma over millionsof years. Typically most (e.g., 75%+) of copper minerals are found assmall crystalline particles in the quartzite and volcanic brecciadepositions in host rocks of the orebody close to the weathered surfacewith the balance disseminated in the host rocks. Chalcopyrite (CuFeS₂)is the most common copper mineral and bornite, covellite and chalcociteare often found in the weathered sections close to the surface.

Most orebodies are heterogeneous with regions of high grade, medium orlow grade ore interspersed with large and small volumes of barren wasterock that may be considered as internal or external dilution of regionsof the ore. In open pit mines the geological boundaries between mineralsof different grades are defined by core drilling and blast hole drillingand inspection of the ore after blasting of blocks of ore. The brokenrock areas after blasting and excavation are delineated by grade forprocessing or disposal as low grade ore or waste rock. The purpose ofore sorting of ore is to separate acceptable grade ore material at adesired average grade, hereinafter “target grade”, from lower grade oreand waste rock for further processing and recovery of valuable minerals.

Bulk ore sorting of batches of ore offers the mine owner the opportunityto economically maximize the recovery and the quality of the ore fromthe mine since the low grade or marginal grade ore, while nothigh-grade, will nevertheless contain portions of ore of desired averagepercent by weight of the copper which could otherwise be wasted and notrecovered. While sorting of ore on a moving conveyor has beenaccomplished heretofore, it has been done at a relatively low speed viathe use of systems and methods such as and including X-ray fluorescenceanalysis, X-Ray Transmission, gamma neutron activation analysis andparticle color sensors to identify particles of ore that containsufficient percent of copper therein. Those sensors are used to sensethe particular ore pieces or particles carried on the conveyor past thesensor and to provide signals to some mechanical or pneumatic device toselect those ore pieces or particles that are deemed to have asufficient percent copper in them and divert the selected pieces forsubsequent collection and use.

The Commonwealth Scientific and Industrial Research Organisation (CSIRO)of Australia has developed a magnetic resonance apparatus or analyzer(MRA) for conducting on-line measurements of ore-bearing rock carried ona moving conveyor to measure the grade of specific elements or mineralsin the ore. International Application WO2017/031537 discloses thatapparatus or analyzer. The MRA can be “tuned’ to rapidly identify andcount the number of chalcopyrite crystals in ore particles independentof the composition of the surrounding rock. In particular, the MRA canbe used to count the number of particles of chalcopyrite in a “slice”consisting of many pieces of ore placed inside the radio frequency coil.If the weight of the ore in the slice is known, the count can beconverted to weight of chalcopyrite in the total mass of material, i.e.,weight % of chalcopyrite. For a given orebody type of host rock andminerals present, the MRA result can be calibrated to calculate thetotal copper content of the slice of ore.

NextOre Pty Ltd, of Australia, a joint venture between CSIRO, RFCAmbrian and Advisian Digital, is presently making available MRA sensorsfor ore sorter systems. The MRA sensor serves to measure the grade of acrushed run-of-mine ore to enable the selection of consecutive slices ofmaterial, hereinafter “pods” of material, with an average total coppercontent above a predetermined cut-off grade from pods of material belowthat cut-off grade to produce higher grade but lower tonnage mill feed.The MRA sensor coil is located surrounding the belt carrying the crushedore pieces bearing the target mineral (the “feed’) to measure thequantity of the target mineral therein. The data resulting from the MRAmeasurement is combined with data from an associated belt weightometerto enable the calculation of the grade of the pod of feed material. Thatinformation can then be used to control a diverter apparatus locatedadjacent the terminus of the conveyor to direct pods of the feedmaterial above a user-specified minimum grade (e.g., a “cut-off grade”)to a station for collection, and pods of the feed material below thatuser-specified cut-off grade to a station for disposal as waste. Themore heterogeneous the ore-bearing material, the more effective thesorter system is owing to the nature of the MRA sensor to identify andmeasure the mineral content of the pods and thereby copper content ofpods that are above or below a cut-off grade.

The MRA sensor is able to quantify the mineral phases of copper-bearingore via the excitation of the mineral phases by a radio frequency (RF)pulse to elicit an echo signal. For example, chalcopyrite has aresonance for copper (Cu) at 18.46 MHz, therefore the strength of theresponse as measured by the sensor can be used to quantify theconcentration of chalcopyrite in the ore.

As will be appreciated by those skilled in the art since the abovedescribed prior art sorting criteria is based on an average cut-offgrade, the portions of the pods which were accepted and collected mayhave more than the desired percentage of the copper therein, and some ofthe portions of the pods passed to waste may have sufficient amounts ofthe copper therein when added to the higher grade pods to result in thesorted ore product having the desired average percentage grade, i.e.,target grade. Thus, if those portions of the pods having sufficientamounts of the copper therein that would have otherwise been relegatedto waste are recovered, they can increase the yield of feed material atthe target grade.

The subject invention provides a means and methods for optimizing yieldsfrom copper-bearing ore utilizing MRA sensing. Thus, if some of thoseportions of the pods that would have otherwise been relegated to wasteare recovered, they can increase the yield at the target grade.Moreover, value can be gained from low-grade stockpiles or resources ofdeclining grade if they are sufficiently heterogeneous to permitseparation of higher grade material from lower grade material. Furtherstill, with the subject invention used to recover higher grade pods fromlower grade ore, one can increase reserves of recoverable ore. The useof this ore sorting system with lower grade material to produceadditional feed to the ore concentrator at the target grade improvesoverall mining recovery without displacing higher grade feed, anddelivers effective reductions in mining costs per unit of metalproduced. Further still, the subject invention enables one to provide ahigher and/or more consistent grade material, more pounds of metal perton of feed material, all the while reducing processing costs, andpossibly reducing plant size and concomitant capital costs to achievethe same or higher level of metal production.

It should be pointed out at this juncture that while the subjectinvention will be described with reference to sorting of copper-bearingores, it is not so limited. Thus, the subject invention can be used foroptimizing the sorting and collection of other metal-bearing ores, e.g.,copper nickel ores, iron ores.

All prior art references cited in this application are specificallyincorporated herein in their entireties

BRIEF SUMMARY OF THE INVENTION

One aspect of this invention is a system for producing pieces of aproduct metal-bearing ore by processing pieces of an input metal-bearingore. The input metal-bearing ore has a metal therein. The productmetal-bearing ore has a desired target average percentage by weight ofthe metal therein. The system comprises a first conveyor, a secondconveyor, a first magnetic resonance analyzing unit and an associatedcontroller, a diverter, and a second magnetic analyzing unit. The firstconveyor is configured to receive the input metal-bearing ore. Thesecond conveyor is configured to carry pieces of the productmetal-bearing ore for collection after the system has processed theinput metal-bearing ore. The first magnetic resonance analyzing unit andan associated controller are configured for measuring the percentage byweight of the metal in the input metal-bearing ore on the first conveyorat successive points in time, calculating the average percentage byweight of the metal in the input metal-bearing ore on the first conveyormeasured over first predetermined length intervals of time, establishinga cut-off value of the average percentage by weight of the metal in theinput metal-bearing ore on the first conveyor for producing the productmetal-bearing ore, producing select signals when the average percentageby weight of the metal in the input metal-bearing ore on the firstconveyor is equal to or greater than the cut-off value, generating anestimate of the average percentage by weight of the metal in the productmetal-bearing ore, and dynamically adjusting the cut-off value up ordown to an adjusted value to produce the select signals if the averagepercentage by weight of the metal in the input metal-bearing ore on thefirst conveyor is below or above the estimate of the average percentageby weight of the metal in the input metal-bearing ore on the firstconveyor. The diverter is configured for receiving the inputmetal-bearing ore from the first conveyor and directing the inputmetal-bearing ore on the first conveyor to a collection path in responseto the select signals when the average percent by weight of the metal inthe input metal-bearing ore on the first conveyor is equal to or greaterthan the adjusted value and directing the input metal-bearing ore on thefirst conveyor to a waste path when the average percent by weight of themetal in the input metal-bearing ore on the first conveyor is less thanthe adjusted value. The second magnetic resonance analyzing unit isconfigured for measuring the percentage by weight of the metal in theproduct metal-bearing ore on the second conveyor and for providing tothe controller signals to fine tune the adjusted value up or down to atuned adjusted value to produce the select signals if the averagepercentage by weight of the metal in the product metal-bearing ore onthe second conveyor is below or above the desired target averagepercentage by weight of the metal in the product metal-bearing ore,thereby causing the diverter to direct the input metal-bearing ore onthe first conveyor to the collection path when the average percent byweight of the metal in the input metal-bearing ore on the first conveyoris equal to or greater than the tuned adjusted value and to direct ofthe input metal-bearing ore on the first conveyor to the waste path whenthe average percent by weight of the metal in the input metal-bearingore on the first conveyor is less than the tuned adjusted value.

In accordance with one preferred aspect of the system of this inventionthe controller is configured for collecting data from the first magneticresonance analyzing unit and organizing that data into trend lines. Eachof the trend lines has a direction and slope and is a line of best fitfor the sequential measurements of the percentage by weight of metal inthe input metal-bearing ore measured over the first predetermined lengthintervals of time on the first conveyor. The controller is configuredfor dynamically adjusting the cut-off value up or down to the adjustedvalue as a function of the direction and slope of the trend lines.

In accordance with another preferred aspect of the system of thisinvention each of the conveyors are at least 75 feet long, wherein thepredetermined speed of the first conveyor is in the range of 180 to 600feet per minute, and wherein the first predetermined period of time isin the range of 1 to 10 seconds.

In accordance with another preferred aspect of the system of thisinvention the metal-bearing ore is copper-bearing ore and wherein themetal is copper.

In accordance with another preferred aspect of the system of thisinvention the desired target average percentage by weight of the copperis approximately 0.3%.

In accordance with another preferred aspect of the system of thisinvention the diverter is a selected from the group consisting of apivoting chute diverter, a diverter gate valve and a flop gate.

In accordance with another preferred aspect of the system of thisinvention the system additionally comprises an ore crusher to reduce thesize of the pieces of the product metal-bearing ore so that they are nogreater than a predetermined maximum size.

In accordance with another preferred aspect of the system of thisinvention the first conveyor, the first magnetic resonance analyzingunit, the controller, and the diverter form an analysis and selectionstation and wherein the system additionally comprises an input sizingstation and a product output station. The input sizing station comprisesa first sizing screen and a first ore crusher. The first sizing screenis configured for receiving the pieces of the input metal-bearing oreand for passing those pieces that are no greater than a firstpredetermined maximum size therethrough to provide processing ore. Thefirst ore crusher being configured to receive pieces of the inputmetal-bearing ore from the first sizing screen that are greater than thefirst predetermined maximum size for crushing those pieces to producethe processing ore and providing the processing ore to the firstconveyor of the analysis and selection station. The input metal-bearingore that is diverted from the first conveyor to the collection pathbeing referred to as selected processing ore. The product output stationforms a portion of the collection path for producing the productmetal-bearing ore and comprises a second ore crusher, a second sizingscreen and a third ore crusher. The second ore crusher is configured toreceive the selected processing ore to reduce the size of the piecesthereof to produce a reduced size selected processing ore. The secondsizing screen is configured for receiving the reduced size selectedprocessing ore and for passing pieces thereof which are no greater thana second predetermined maximum size therethrough to the second conveyoras the product metal-bearing ore. The second predetermined maximum sizeis less than the first predetermined maximum size. The third ore crusheris configured to receive pieces of the reduced size selected processingore greater than the second predetermined maximum size from the secondsizing screen for crushing the pieces of the reduced size selectedprocessing ore to produce crushed pieces and providing the crushedpieces back to the second sizing screen.

In accordance with another preferred aspect of the system of thisinvention the input sizing station also comprises a preliminary sizingscreen and a preliminary ore crusher. The preliminary sizing screen isconfigured for providing pieces of the input metal-bearing ore that areno greater than a third predetermined maximum size to the first sizingscreen. The third predetermined maximum size is greater than the firstpredetermined maximum size. The preliminary sizing screen providespieces of the input metal-bearing ore which are greater than the thirdpredetermined maximum size to the preliminary ore crusher. Thepreliminary ore crusher is configured to crush the pieces of the inputmetal-bearing ore from the preliminary sizing screen that are greaterthan the third predetermined maximum size to a crushed size ore whichcan be provided back to the preliminary sizing screen.

In accordance with another preferred aspect of the system of thisinvention the input metal-bearing ore comprises copper-bearing ore, andwherein the first predetermined maximum size is approximately 150 mm,the second predetermined maximum size is approximately 10 mm, and thethird predetermined maximum size is approximately 450 mm.

In accordance with another preferred aspect of the system of thisinvention the input sizing station additionally comprises an apronfeeder located between the preliminary sizing screen and the firstsizing screen. The apron feeder controls the rate at which the inputmetal-bearing ore whose pieces are no greater than the thirdpredetermined maximum size are provided to the first sizing screen underthe control of a first weighing device. The first weighing device islocated adjacent the first conveyor and the first magnetic resonanceanalyzing unit.

In accordance with another preferred aspect of the system of thisinvention the first magnetic resonance analyzing unit includes a coilhaving an internal cross sectional area, and wherein the input sizingstation additionally comprises a surge bin configured for receiving theinput metal-bearing ore that is no greater than the first predeterminedsize and for providing such ore to the first conveyor at a controlledrate. The controlled rate results in the amount of input metal-bearingore on said first conveyor being maintained at approximately 20-30% ofthe internal cross-sectional area of the coil of the first magneticresonance analyzing unit.

In accordance with another preferred aspect of the system of thisinvention the second conveyor and the second analyzer form a portion ofthe product output station.

In accordance with another preferred aspect of the system of thisinvention the second magnetic resonance analyzing unit includes a coilhaving an internal cross-sectional area, and wherein said output sizingstation additionally comprises a surge bin configured for receiving theselected processing ore from the analysis and selection station. Theselected processing ore is processed in the output sizing station toensure the size of pieces of the selected processing ore do not exceed apredetermined maximum size to produce the product metal-bearing ore andfor providing the product metal-bearing ore to the second conveyor at acontrolled rate. The controlled rate results in the amount of productmetal-bearing ore on the second conveyor being maintained atapproximately 20-30% of the internal cross-sectional area of the coil ofthe second magnetic resonance analyzing unit.

In accordance with another preferred aspect of the system of thisinvention the system additionally comprises a waste output stationforming a portion of the waste path, wherein the waste output stationcomprises a waste ore crusher configured to crush the inputmetal-bearing in said waste path into waste ore pieces having a maximumpredetermined size.

In accordance with another preferred aspect of the system of thisinvention the maximum predetermined size of the waste ore pieces is upto approximately 50 mm.

Another aspect of this invention is a method for producing pieces of aproduct metal-bearing ore by processing pieces of an input metal-bearingore. The input metal-bearing ore has a metal therein. The productmetal-bearing ore has a desired target average percentage by weight ofthe metal therein. The method comprises providing the metal-bearing oreon a first conveyor. The percentage by weight of the metal in the inputmetal-bearing ore on the first conveyor is measured at successive pointsin time. The average percentage by weight of the metal in the inputmetal-bearing ore on the first conveyor measured over firstpredetermined length intervals of time is calculated. A cut-off value ofthe average percentage by weight of the metal in the input metal-bearingore on the first conveyor for producing the product metal-bearing ore isestablished. Select signals when the average percentage by weight of themetal in the input metal-bearing ore on the first conveyor is equal toor greater than the cut-off value are produced. An estimate of theaverage percentage by weight of the metal in the product metal-bearingore is generated. The cut-off value is dynamically adjusted up or downto an adjusted value to produce the select signals if the averagepercentage by weight of the metal in the input metal-bearing ore on thefirst conveyor is below or above the estimate of the average percentageby weight of the metal in the input metal-bearing ore on the firstconveyor. The input metal-bearing ore on the first conveyor is directedto a collection path in response to the select signals when the averagepercent by weight of the metal in the input metal-bearing ore on thefirst conveyor is equal to or greater than the adjusted value. The inputmetal-bearing ore on the first conveyor is directed to a waste path whenthe average percent by weight of the metal in the input metal-bearingore on the first conveyor is less than the adjusted value. Thepercentage by weight of the metal in the product metal-bearing ore on asecond conveyor is measured and the adjusted value is fine tuned up ordown to a tuned adjusted value to produce the select signals if theaverage percentage by weight of the metal in the product metal-bearingore on the second conveyor is below or above the desired target averagepercentage by weight of the metal in the product metal-bearing ore,whereupon the input metal-bearing ore on the first conveyor is directedto the collection path when the average percent by weight of the metalin the input metal-bearing ore on the first conveyor is equal to orgreater than the tuned adjusted value and the input metal-bearing ore onthe first conveyor is directed to the waste path when the averagepercent by weight of the metal in the input metal-bearing ore on thefirst conveyor is less than the tuned adjusted value.

In accordance with one preferred aspect of the method of this inventionthe method comprises dynamically adjusting the cut-off value up or downto the adjusted value as a function of a direction and slope of trendlines. Each of the trend lines is a line of best fit of the sequentialmeasurements of the percentage by weight of metal in the inputmetal-bearing ore measured over the first predetermined length intervalsof time on the first conveyor.

In accordance with another preferred aspect of the method of thisinvention the metal-bearing ore is copper-bearing ore and wherein themetal is copper.

In accordance with another preferred aspect of the method of thisinvention the desired target average percentage by weight of the copperis 0.3%.

In accordance with another preferred aspect of the method of thisinvention the method additionally comprises preliminarily sizing thepieces of the input metal-bearing ore so that the pieces thereof are nogreater than a first predetermined maximum size and providing thosepieces to the first conveyor. The pieces of the input metal-bearing oreprovided to the collection path are sized so that the pieces thereof areno greater than a second predetermined maximum size. The secondpredetermined size is less than the first predetermined maximum size.The pieces of the input metal-bearing ore that are no greater than thesecond predetermined maximum size are provided to the second conveyor.

In accordance with another preferred aspect of the method of thisinvention the preliminary sizing of the pieces of the inputmetal-bearing ore comprises screening pieces of the input metal-bearingore, whereupon pieces of that ore which are no greater than a thirdpredetermined maximum size are introduced to the first conveyor. Thethird predetermined maximum size is greater than the first predeterminedmaximum size. The size of the pieces of the input metal-bearing ore thatare greater than the third predetermined maximum size are reduced insize to a size which is no greater than the third predetermined maximumsize for introduction to the first conveyor.

In accordance with another preferred aspect of the method of thisinvention the metal-bearing ore comprises copper-bearing ore and themetal is copper. The first predetermined maximum size is approximately150 mm, the second predetermined maximum size is approximately 10 mm,and the third predetermined maximum size is approximately 450 mm.

In accordance with another preferred aspect of the method of thisinvention the method additionally comprises controlling a rate at whichthe pieces of the input metal-bearing ore which are no greater than thethird predetermined maximum size are screened.

In accordance with another preferred aspect of the method of thisinvention the first magnetic resonance analyzing unit includes a coilhaving an internal cross sectional area, and wherein the methodadditionally comprises providing the pieces of the input metal-bearingore that are no greater than the first predetermined size to the firstconveyor at a controlled rate so that the amount of the inputmetal-bearing ore on the first conveyor is maintained at approximately20-30% of the internal cross sectional area of said first magneticresonance analyzing unit.

In accordance with another preferred aspect of the method of thisinvention the second magnetic resonance analyzing unit includes a coilhaving an internal cross sectional area, and wherein the methodadditionally comprises providing the pieces of the product metal-bearingore that are no greater than the second predetermined size on the secondconveyor at a controlled rate so that the amount of the productmetal-bearing ore on the second conveyor is maintained at approximately20-30% of the internal cross sectional area of the second magneticresonance analyzing unit.

In accordance with another preferred aspect of the method of thisinvention the method additionally comprises sizing the pieces of theinput metal-bearing ore in the waste path so that the pieces thereof areno greater than a fourth predetermined maximum size.

In accordance with another preferred aspect of the method of thisinvention the fourth maximum predetermined size is approximately 50 mm.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an illustrative diagram showing one exemplary embodiment ofthe sorting system of this invention for sorting and collectingcopper-bearing ore having a desired target value of average weightpercent of copper therein from copper-bearing ore provided to thesystem;

FIG. 2 is an illustrative diagram of the product output station of FIG.1 ;

FIG. 3A is an illustration of a pivoting chute diverter forming aportion of the system of FIG. 1 , with the diverter being shown in theposition wherein it is diverting pods of the desired percentagecopper-bearing ore from the ore for subsequent collection;

FIG. 3B is an illustration like that of FIG. 3A by showing the chutediverter in the position wherein it is diverting ore not having thedesired average weight percent of copper therein for waste;

FIG. 4 is a graph of the average weight percentage of copper in thecopper-bearing ore plotted against time and made up of plural datapoints as determined by a first magnetic resonance analyzer unit whichforms a portion of the sorting system of FIG. 1 ;

FIG. 5 is a graph like that of FIG. 4 , but showing the operatingparameters of a controller which also forms a portion of the sortingsystem of FIG. 1 and which is coupled to the first magnetic analyzer toprovide feedback data using slope of consecutive analysis data from themagnetic resonance analyzer and associated weighing device todynamically adjust the cut-off value used to direct the operation of thediverter;

FIG. 6 an illustrative diagram showing another exemplary embodiment of asorting system of this invention including an ore sizing station, ananalysis and selection station, a product output station, and a wasteoutput station, the system being configured for sorting and collectingcopper-bearing ore having a desired target value of average weightpercent of copper therein from copper-bearing ore provided to thesystem, for sizing the ore from the mine, sizing the output ore, andsizing the waste product;

FIG. 7 is an illustrative diagram of the sizing station of FIG. 6 ; and

FIG. 8 is an illustrative diagram of the product output station of FIG.6 .

DETAILED DESCRIPTION OF EXEMPLARY PREFERRED EMBODIMENTS OF THE INVENTION

Referring now to the various figures of the drawing wherein likereference characters refer to like parts, there is shown in FIG. 1 oneexemplary sorting system 20 constructed in accordance with thisinvention. The sorting system 20 is particularly suited for use insorting copper-bearing ore, but can be used for sorting othermetal-bearing ores. In any case the system 20 is configured to be usedto sort low grade or marginal grade ore produced at a mine into orehaving a desired average weight percentage content of valuable metal.For copper from a low-grade porphyry orebody, an ore having an averagecopper content of 0.3% by weight is typically acceptable commerciallyfor further processing and concentration of copper minerals andsubsequent smelting to copper metal. It should be noted that theacceptable weight percentage will vary from mine to mine, depending upona number of various factors. Thus, the target average copper content of0.3% as used herein is merely exemplary.

As can be seen in FIG. 1 , the sorting system 20 includes an input beltconveyor 22 onto which the input metal-bearing ore, e.g., copper-bearingore from a mine, to be sorted is placed. That ore is carried on theconveyor in the direction shown by the arrow under a magnet 24. Themagnet is located at the exit end portion of the conveyor 22 to attractany ferrous material that may be on the conveyor's belt so that suchferrous material does not pass with the ore for sorting. The pieces ofore drop off the exit end of the conveyor 22, whereupon they fall ontoanother conveyor 28 at the input end thereof. The conveyor 28 may bereferred to as a feed conveyor and is preferably a cloth reinforced beltconveyor of conventional construction as this works best with the MRanalyzer. Preferably, the feed conveyor 28 is a long, e.g., 75 to 150feet length, device whose circulating belt moves the ore deposited onthe upper surface thereof in the direction of the arrow shown at apredetermined rate of speed, e.g., belt speeds of 500 to 600 feet perminute, and with ore loading of 200 tons per hour up to 2,000 tons perhour.

The ore deposited on the feed conveyor 28 then passes under anadjustable height barrier 30. The barrier 30 is located upstream of afirst magnetic resonance analyzer unit 32. The first magnetic resonanceanalyzer unit 32 includes a conventional belt scale or belt weighingdevice 32A, sometimes referred to as a “weightometer”, and a firstmagnetic resonance analyzer 32B. The adjustable height barrier 30 servesto prevent any pieces of ore on the belt that extend upward beyond apredetermined height from reaching the analyzer 32B, since such piecescould damage the analyzer. In particular, the barrier 30 serves to“smooth out” the ore on the conveyor to an acceptable height by blockingany pieces of ore extending too high from the belt and causing suchpieces to find a position on the belt where they will not extend upwardbeyond the desired height in order to protect the analyzer.

The belt scale or weightometer 32A of the analyzer unit 32 produceselectrical signals representative of the mass of the ore carried by themoving belt of the feed conveyor 28. The magnetic resonance analyzer 32Bis located adjacent, e.g., slightly downstream of the weightometer 32A.As will be described in more detail later, the analyzer 32B measures thecontent of the copper minerals in the pieces of the ore passing throughits coil, whereupon the analyzer unit 32B provides first electricaloutput signals representative of the weight percent of copper in thatore in first predetermined length intervals of time, with eachpredetermined length interval of time representing a pod on the feedconveyor 28. In one exemplary embodiment of this invention thepredetermined speed of the feed conveyor 28 is in the range of 180 feetper minute to 600 feet per minute, and the first predetermined lengthinterval of time is in the range of 1 to 20 seconds. The first outputelectrical signals are provided to a controller 34. Preferably thecontroller is a programmable logic controller (PLC) suitable for use ina dusty industrial environment like a mine. Some of details of the PLCcontroller will be described later. Suffice it for now to state that thecontroller 34 establishes sorting criteria for deciding when portions orpods of the marginal ore on the feed conveyor 28 are to be selected tobe passed to a product path for collection and subsequent processing(e.g., refining into copper), or are to be passed on to waste path fordisposal.

The output end of the feed conveyor 28, which is in the form of a pulley28A about which the conveyor's belt 28B extends, is located within theinterior of a diverter chute 36 as best seen in FIGS. 3A and 3B andwhich will be described in detail later. Thus the ore exiting theconveyor 28 drops through the diverter chute 36 into the inlet of apivoting chute type diverter 38. The details of the pivoting chutediverter 38 will also be described later with respect to FIGS. 2 and 3 .Suffice it for now to state that the pivoting chute diverter 38 includesa pivotable spout 38A which is configured to be pivoted from oneposition (hereinafter referred to as the “select” position) to anotherposition (hereinafter referred to as the “waste” position), and viceversa, under control of the controller 34 in accordance with the sortingcriteria. In particular, when the controller 34 determines that a pod ofmarginal ore on the conveyor 28 does not meet the sorting criteria thepivoting spout 38A will be pivoted to the waste position so that the orepieces of that pod pass out of a waste outlet chute 38B of the diverter38 onto a waste conveyor 40 in the waste path. The waste conveyor 40 canbe of any type of construction and is configured to carry the wastepieces of ore to a station for disposal. In the exemplary embodimentshown the exit end of the waste conveyor serves to drop the waste oreinto a bin 42, from which that ore can be loaded into the bed of a dumptruck 44 for disposal.

Those pods of ore that are determined to meet the sorting criteria bythe controller 34 are directed into a “collection” or “product” path bythe diverter 38. In particular, when the controller determines that apod of ore on the feed conveyor 28 meets the sorting criteria, thecontroller provides a signal indicative thereof, hereinafter called a“select” signal, to the diverter 38, to cause its pivotable chute 38A topivot to the select position. With the spout in that position the orepieces of the pod will drop out of what can be called the select outletchute 38D of the diverter 38 and into a bin 46 forming a portion of theproduct path. The bin 46 includes a vibrating feeder 48, wherefrom theselected ore drops onto another conveyor 50. The conveyor 50 is aconventional conveyor of any suitable construction, preferably a clothreinforced belt conveyor as this works best with the MR analyzer. Thus,the ore from the diverter referred to as the “product metal-bearing ore”is carried on the belt of the conveyor 50 in the direction of the arrowshown below that conveyor for introduction into a Product Output Station60.

The Product Output Station 60 is configured for receiving themetal-bearing ore having the desired average target grade of metal(e.g., copper) therein that is on the conveyor 50 (hereinafter referredto as the “selected processing ore” for sizing the pieces of thereof sothat none exceeds a desired predetermined maximum (e.g., 10 mm). By sodoing one is able to produce a metal-bearing ore, hereinafter referredto as the “product metal-bearing ore”, that it particularly suitable forfurther processing, e.g., to extract the metal thereof.

The Product Output Station 60 is best seen in FIG. 2 and basicallycomprises an adjustable height barrier 52, a second magnetic resonanceanalyzer unit 54 (made up of a second weightometer 54A and a secondmagnetic resonance analyzer 54B like the first magnetic resonanceanalyzer unit), an ore crusher 62, a conveyor 64, a single deck sizingscreen 66, a conveyor 68, a surge bin 70, another ore crusher 72, aconveyor 74 and a fine ore bin building 76. The ore crusher 62 is aconventional unit which is configured to crush the selected processingore from the conveyor 50 into smaller pieces, which are deposited on theconveyor 64, from whence they are carried to the sizing screen 66. Thosepieces of ore which do not exceed a predetermined maximum size, e.g., 10mm, pass through the screen 66 from whence they drop onto the conveyor68, hereinafter referred to as the “product conveyor” which carriesthose pieces of ore to the interior of the fine ore bin building 76.Those pieces of ore form the final product of the system 20 and are ofthe desired target grade and desired size for subsequent processing,e.g., grinding, floatation and smelting.

Those pieces of selected processing ore which are greater than thepredetermined maximum size are provided by the sizing screen 66 to thesurge bin 70, and from there to the ore crusher 72 The ore crusher 72 isalso a conventional unit and serves to crush the ore delivered to itinto smaller pieces, which are deposited on the conveyor 74 and carriedback to the sizing screen 66. Accordingly those pieces which do notexceed the predetermined maximum size, e.g., 10 mm, pass through thesizing screen 66 onto the conveyor and from there to the fine ore binbuilding 76. Those pieces which still exceed the predetermined maximumsize, e.g., 10 mm, are again directed to the surge bin 70 and from thereto the tertiary ore crusher 72. Thus, those pieces of the selectedprocessing ore that are greater than the first predetermined maximumsize are provided to the ore crusher 72 for crushing into crushed piecesand the crushed pieces are re-united with the ore pieces below thatfirst predetermined maximum size on the product conveyor 68. The surgebin 70 includes a level sensor and is provided between the sizing screen66 and the ore crusher 72 to ensure that the rate of delivery of the oreto the ore crusher 72 is optimized.

As mentioned above, the second magnetic resonance analyzer unit 54 isconstructed like the first magnetic resonance analyzer unit 32 and thusincludes a second weightometer 54A and a second magnetic resonanceanalyzer 54B. The second weightometer is located slightly upstream ofthe second magnetic resonance analyzer 54B. The second magneticresonance analyzer 54B measures the content of the copper in the piecesof the product ore passing through its coil, whereupon it providessecond electrical output signals to the controller 34 which arerepresentative of the actual weight percent of copper in the product orein second predetermined length intervals of time, with each such secondpredetermined length interval of time representing a group of pods onthe product conveyor 68. In accordance with one exemplary aspect of thisinvention the predetermined speed of the conveyor 68 is in the range of180 feet per minute to 600 feet per minute, and the second predeterminedlength interval of time is in the range of 20 to 300 seconds.

Each of the magnetic resonance analyzers 32B and 54B is preferablyconstructed in accordance with the teachings of the aforementioned CSIROInternational Application WO2017/031537 and use high frequency radiowaves to rapidly measure the copper mineral content of all of the piecesof ore on the associated conveyor's belt as they pass through theanalyzer's coil (not shown). Each of the analyzer's coils has apredetermined internal cross-sectional area which is designed tocompletely surround the conveyor belt. Each analyzer provides electricaloutput echo signals representative of the concentration of the selectedor target mineral phase of copper, e.g., chalcopyrite, in the ore to thecontroller 34. That controller includes a computer (not shown) andassociated software (not shown) and is configured to receive electricalsignals from the weightometers 32A and 54A and the analyzers 32B and54B, respectively, to calculate the average percentage by weight of aparticular, and preselected, copper bearing mineral, e.g., chalcopyrite,in the ore on the conveyors 28 and 68, respectively, over separatelypredetermined length intervals of time, i.e., the first predeterminedlength intervals of time and the second predetermined length intervalsof time, respectively.

Each analyzer unit is capable of providing accurate measurement of thecopper content of the ore on the associated conveyor's belt veryquickly. Thus, the counting measurement is very fast, e.g., about 0.1millisecond per slice of the cross-section of ore on the belt. In orderto develop meaningful analyses for industrially meaningful weight ofore, the analyses of individual slices are accumulated to accuratelydefine the average copper content of a larger mass of ore. For example,the analyzer units can be set up to calculate copper content of the oreas weight percent averaged every 2-5 seconds for a pod size of about0.66-1.65 tons at a 1,200 tons per hour feed rate.

As will be appreciated by those skilled in the art the analyzer units 32and 54 have to operate with a desired fill factor of ore on theirassociated conveyors 28 and 68, respectively, to ensure that theyprovide an accurate analysis of the ore on those conveyors. Inparticular, the analyzer units of the subject invention require that thecross-section area of the ore material on the conveyors 28 and 68 bekept relatively constant, e.g., be approximately 20%-30% of thecross-section area of the interior of the MR analyzer's coil. Thus,collection or surge hoppers are provided in the system 20 to ensure thatthe ore on the conveyors 32 and 68 is at the desired fill factor.

The first magnetic resonance analyzer unit 32B has three purposes. Thefirst purpose is to determine the average weight percent of copper inthe pods of marginal copper-bearing ore on the conveyor 28 and forproviding electrical signals indicative thereof to the controller 34. Tothat end, the first magnetic resonance analyzer unit 32 measures thecopper weight percent content of the slices of copper ore on the feedconveyor 28 and averages the data over integration periods ofapproximately 2-5 seconds, as selected by the operator and input intothe controller. The average analysis is for a specific weight of ore(pod) as measured by the associated belt weighing device 32A withaccuracy less than about 1%, preferably less than 0.5%. That data isprovided by electrical signals to the controller 34.

FIG. 4 is an exemplary graph showing a plot of values of the measuredpercentage by weight of copper in the copper-bearing ore on the feedconveyor 28 as a function of time, with each of the data pointscollected to produce the plot representing the average copper contentfor a 2-5 second integration period with each point representing theaverage copper content of ore equivalent to one pod of a 0.66-1.65 tonssize. Thus, it can be seen that the percentage by weight of copper forthe successive pods represented range from approximately 0.08% to 1.2%.

The second purpose of the first analyzer unit 32B is to determine if theaverage weight percent of the marginal ore on the first conveyor 28meets or exceeds a predetermined copper content value (which may also bereferred to as a cut-off point) which is input into the controller bythe user of the sorting system 20, e.g., the plant operator. If theaverage weight percent of the marginal ore measured over a firstpredetermined length interval of time meets or exceeds the predeterminedcut-off value, the controller provides the heretofore identified“select” signal. That signal is provided to the diverter 38 to cause thepivoting spout 38A of the diverter 38 to be moved to position like shownin FIG. 2 , whereupon the marginal ore on the feed conveyor 28 will besent to the product path, e.g., to the product conveyor 52.

The predetermined cut-off value forms part of the heretofore mentionedsorting criteria. For example, if the user of the system 20 wishes tocollect ore having an average weight percent of 0.3, shown by thehorizontal line X in FIG. 5 , the controller 34 will be set to a cut-offvalue that the user believes will result in that desired weight percent.In the example of FIG. 4 , the initial cut-off value is 0.175% shown bythe horizontal line Y in FIG. 5 . The cut-off value is initially set bythe plant operator or user based on copper analysis information providedby exploration drill-core and blast-hole samples which resulted in thedelineating the location of the marginal ore.

The third purpose of the first analyzer unit 32 is to feed back anelectrical signal representative of the estimated average copper contentof the product metal-bearing ore on the second conveyor 68 todynamically adjust the cut-off value of the select signal from thecontroller up or down to an adjusted value, if necessary, to result in adesired target average copper grade of ore to be collected. Inparticular, if for the example given above, the desired target grade ofmarginal ore to be sorted and collected for further processing is tohave an average weight percent of 0.3, and the initial setting of thecut-off value or set-point of 0.175 percent results in product orehaving an estimated average weight percent of 0.4 percent from themeasured over the predetermined length interval of time, the feedbacksignal provided by the analyzer unit 32B to the controller 34 willadjust the controller's cut-off value down to an adjusted value that isbelow 0.175% to bring the average weight percent of copper of theproduct ore over a second predetermined length interval of time down tothe desired 0.3%. This action will allow more product ore to becollected, thereby increasing the yield and resulting in a moreconsistent analysis of the product. Conversely, if the feedback signalprovided indicates that the product ore pods have an actual averageweight percent of 0.28, the feedback signal provided by the analyzerunit 32B to the controller will adjust the controller's cut-off value toan adjusted value that is above the 0.175% set point to bring theaverage weight percent of the product ore up to the desired target valueof 0.3%.

The controller 34 may also be configured so that the select signal forthe diverter 38 produced by the controller 34 may also be based on usingwhat can be called “trend lines” of the individual measurements over thefirst predetermined length interval of time of the metal, e.g, copper,content of the ore percentages on feed conveyor 28 as part of thesorting criteria to dynamically control the diverter. Thus, thecontroller 34 can use the copper percentage analysis data to prepare arunning average trend line for the copper content of the marginal gradeore on the conveyor 28 to dynamically adjust the cut-off value up ordown to the adjusted value as a function of the trend lines. Forexample, as can be seen in FIG. 5 a plurality of trend lines are shownby thick broken lines Z. Each of the lines Z represents trends showinghow the percentage content is increasing or decreasing as the pods ofthe ore on the feed conveyor travel through the first analyzer unit 32B.Thus, each of the trend lines has a direction and slope, and each of thetrend lines is defined by a line of best fit for the sequential valuesof the first electrical signals making up that trend line. Thevariations in the direction and slope of the trend lines are used by thecontroller 34 to determine whether or not to further adjust the adjustedvalue. Eleven such trend lines are shown in FIG. 5 and are labeled as Ato L. In the example shown in FIG. 5 , when the trend line is headingupwards such as E to F or G to H, the controller 34 can be set to directthe diverter 38 to send more marginal ore to the product path and lessto waste path. The reason for this is that when the ore contains ahigher copper percent content one can increase copper recovery from theore while ensuring that the product ore sent to the product conveyor 68is close to an average copper content of 0.3% of the product over asecond predetermined length interval of time. When the trend line isheading down such as D to E and F to G, the controller can be used todirect the diverter to allow less marginal ore to go to product path andmore to the waste path. Again, this is so that the average coppercontent of the ore over the second predetermined length interval of timesent to the product stockpile is close to the required average 0.3%copper content of the product.

As mentioned earlier the second analyzer unit magnetic resonanceanalyzer 54B is constructed similarly to the first unit 32B. It has twopurposes. The first purpose is to analyze the product copper content ofore material on the product conveyor 68 to determine the actual averagecopper content percent by weight of the ore passing through the magneticanalyzer over a second predetermined length interval of time and forproviding to the controller 34 second electrical signals indicative ofthe average percentage by weight of metal in the metal-bearing ore onthe product conveyor measured over the second predetermined lengthintervals of time, thus providing the actual measured values for theaverage metal in the product metal-bearing ore. This should confirm theestimated average metal in the product metal-bearing ore determined fromthe measurements of the input metal-bearing ore on the feed conveyor 28before the input metal-bearing ore with an average metal above the cutoff was separated at the diverter.

The second purpose of the second analyzer 54B is to feedback the actualmeasured average percentage of metal in the product metal-bearing ore toact as a calibration or fine-tune adjustment for the estimated averagemetal content in the product metal bearing ore measured at the firstanalyzer. In particular, the second magnetic resonance analyzing unit MBis configured for measuring the percentage by weight of the metal in theproduct metal-bearing ore on the product conveyor 68 and for providingto the controller 34 signals to fine tune the adjusted value up or downto a tuned adjusted value to produce the select signals if the averagepercentage by weight of the metal in the product metal-bearing ore onthe second conveyor is below or above the desired target averagepercentage by weight of the metal in the product metal-bearing ore. Thataction causes the diverter 38 to direct the input metal-bearing ore onthe feed conveyor 28 to the collection path when the average percent byweight of the metal in the input metal-bearing ore on that conveyor isequal to or greater than the tuned adjusted value and to direct of theinput metal-bearing ore on that conveyor to the waste path when theaverage percent by weight of the metal in the input metal-bearing ore onthat conveyor is less than the tuned adjusted value.

Since the separation mechanism at the diverter 38 may result in loss ofsome input metal-bearing ore that should have gone to the collectionpath, but which spilled to the waste path, or the gain of some inputmetal-bearing ore that should have gone to the waste path, but whichspilled to the collection path, it is possible that the measured andestimated values are not completely consistent over a pre-determinedtime period and therefore this second analysis is essential to both knowthe metal content in the product metal-bearing ore over a givenrelatively long time period, e.g., fifteen minutes, and be able to makenecessary adjustments to optimize or fine-tune the adjusted value forthe desired product output. An example would be dynamically changing thetime interval for the measurement on the first analyzer to increase ordecrease the weight of a pod of material to regulate the frequency ofchanging the diverter flow.

Turning now to FIGS. 2 and 3 , the details of the construction andoperation of the diverter chute 36 and the pivoting chute diverter 38will now be described. As can be seen the diverter chute 36 is a hollowhousing having an opening 36A through which the output end of the feedconveyor 28 extends so that the portion of the belt 28B extending aboutthe head pulley 28A, is located within the interior of a diverter chute36.

As mentioned above the diverter 38 is preferably a pivoting chute typediverter. One particularly suitable diverter is available from VortexGlobal Corporation, Salina Kansas USA under the model designation “TitanSeries”. The Titan Series of pivoting chute diverters are designed toreceive a vertically falling stream of ore pieces at their inlet. Thus,the outlet chute 36A of the diverter chute is coupled to the inlet ofthe diverter 38. The inlet of the diverter 38 leads to a pivoting spout38A, which is pivoted from side to side by a lever arm 38B coupled to ahydraulic actuator 38C. The diverter includes two outlet chutes, namelya “product” chute 38D and a “waste” chute 38E. The product chute 38D isopen at its bottom and is arranged to receive ore from the pivotingspout when the spout is in the position shown in FIG. 2 to pass the oreinto the product path. The waste chute 38E is open at its bottom and isarranged to receive ore from the pivoting spout when the spout is in theposition shown in FIG. 3 to pass the ore into the waste path.

The hydraulic actuator is under control of electrical signals from thePLC controller 34. In particular, when the controller produces theheretofore mentioned select signal, the actuator will pivot the spout38A to the position shown in FIG. 2 , whereupon the ore pieces exitingthe spout will drop out of the spout and pass through the product chute38D into the bin 46. Otherwise the spout will be in position shown inFIG. 3 , whereupon the ore pieces exiting the spout will drop out of thespout and pass through the waste chute 38E to the conveyor 40. Thehydraulic actuator's stroke movement and speed can be controlled tosplit the discharge from the feed conveyor 28 to either chute 38D or 38Eas required under the control of the controller 34.

Since fine ore particles or pieces, commonly known as “fines” belowabout 4 mesh Tyler screen size tend to stick to the belt 28B so as to becarried around the head pulley 28A further than coarser ore particles orpieces, the chute diverter 36 includes a belt scraper 28C. The beltscraper 28C is located immediately adjacent the belt 28B at the headpulley 28A to scrape off any fines which would tend to stick to the belt28B as it is carried around the head pulley 28A.

The following are some commercially available components that can beused for an implementation of the exemplary sorting system 20 describedabove.

-   -   Magnet 24—Eriez Manufacturing Company (USA)    -   Magnetic Resonance Analyzers 32B and 55B—NextOre Pty Ltd,        Australia    -   Belt weightometers 32A and 54A (including belt speed measurement        device and calibration check weights and calibrating        mechanism)—Siemens Milltronics (Germany/USA), Thermo Scientific        Ramsey (USA), and Thayer Scale, Hyer Industries, Inc. (USA)    -   Diverter 38 (including hydraulic actuator and pumping system and        controls)—Vortex Global Inc. (USA)    -   Belt scraper 28C—Martin Engineering (USA)

Turning now to FIGS. 6-9 , there is shown another exemplary, and morepreferred, embodiment 100 of a sorting system constructed in accordancewith this invention. The sorting system 100 includes an Ore SizingStation 102, an Analysis And Selection Station 104, the heretoforedescribed Product Output Station 60, and a Waste Output Station 108.Each of those stations will be described in detail later, except for theProduct Output Station 60 since it has been described earlier withrespect to system 20.

Suffice it for now to state that the Ore Sizing Station 102 isconfigured for receiving ore, e.g., copper-bearing ore, from a mine andfor sizing that ore, i.e., reducing the size of the pieces of ore sothat none exceeds a desired predetermined maximum size (e.g., 150 mm).The sizing of the ore enables it to be efficiently analyzed and sorted(selected) by the Analysis And Selection Station 104. The Analysis AndSelection Station 104 is identical in construction and operation to theportion of the system 20 that effects the analyzing and sorting(selecting) of the ore as described above, i.e., the components 28, 30,32, 34, 36, 38, 46, 48, 50, 52 and 54. Thus, in the interest of brevitythe common components the Analysis And Selection Station 104 of thesystem 100 and the corresponding portion of the system 20 will be giventhe same reference numbers, and the construction, arrangement andoperation of those components will not be described in detail orreiterated herein. So too, since the Product Output Station 60 of thesystem 100 is identical to the Product Output Station 60 of the system100 the components of the Product Output Station 60 of the system 100will be given the same reference numbers, and the construction,arrangement and operation of those components will not be described indetail or reiterated herein. Thus, all that will be said about theProduct Output Station 60 of the system 100 is that it is configured forreceiving processed ore, i.e., metal-bearing ore having the desiredaverage target grade of metal, e.g., copper, therein, from the AnalysisAnd Selection Station 104 and sizing that ore, i.e., reducing the sizeof the pieces of the ore so that none exceeds a desired predeterminedmaximum (e.g., 10 mm). By so doing one is able to produce ametal-bearing ore that it particularly suitable for further processing,e.g., to extract the metal therefrom.

The Waste Output Station 108 is configured for the receiving waste ore,i.e., the metal-bearing ore having less than the desired average targetgrade of metal therein, from the Analysis And Selection Station 104 andsizing that waste ore, i.e., reducing the size of the pieces of the oreso that none exceeds a desired predetermined maximum. By so doing onecan use the waste material economically, e.g., as an aggregate sub-baseof road beds, etc. For such a use the predetermined maximum size of thepieces of waste ore is approximately 50 mm.

Turning now to FIG. 7 , the details of the Ore Sizing Station 102 willnow be described. That station basically comprises a static grid orscreen 110, a feed bin 112, an apron feeder 114, a drop ball crusher116, a grizzly screen 118, a magnet 24 (like the magnet 24 of the system20), a primary ore crusher 120, a conveyor 122, and a surge bin 124. Thestatic grid or screen 110 is disposed over the feed bin 112, isconfigured to enable pieces of metal-bearing ore which are no greaterthan a predetermined maximum size, e.g., 450 mm, to pass therethroughinto the feed bin 112. The feed bin can be of any size. One exemplarysize is 120 cubic meters. The metal-bearing ore is delivered to thestatic grid or screen 110 from a mine by a dump truck 44. The outlet ofthe feed bin 112 is the apron feeder 114, which is configured to carrythe pieces of the ore that are no greater than the predetermined maximumsize to the grizzly screen 118. That screen forms the first sizingscreen of the Ore Sizing Station 102. Pieces of ore which are greaterthan the predetermined maximum size (identified as “OVERSIZED ORE” inFIG. 7 ) are provided into a pile 116A under the drop ball ore crusher116. The ball of that device is configured to be dropped onto the pile116A to crush the metal-bearing ore pieces of the pile into smallerpieces. Those crushed smaller pieces (identified as “PRELIMINARY CRUSHEDORE” in FIG. 7 ) are then carried back to the preliminary sizing screen112, so that pieces thereof which are less than or equal to thepredetermined maximum size drop into the bin 110, from whence they passto the apron feeder. Any pieces of the preliminary crushed ore which arestill greater than the predetermined maximum size are brought back fromthe pile 116A to be crushed again by the ball crusher and the resultingpreliminary crushed ore brought back to the preliminary sizing screen.

The grizzly screen 118 is configured to enable pieces of themetal-bearing ore deposited on it by the apron feeder 114 which are notgreater than a predetermined maximum size, e.g., 150 mm, to passtherethrough, from whence they fall onto the conveyor 122. That conveyoris a belt conveyor of conventional construction, which includes acirculating belt to carry the ore deposited on its upper surface thereofin the direction of the arrow shown at a predetermined rate of speed tothe surge bin 124. Those pieces of metal-bearing ore which are greaterthan that predetermined maximum size are carried past the magnet 24,which removes any ferrous materials from the metal-bearing ore. Thepieces of ferrous-free metal-bearing ore are provided to the primary orecrusher 120. That device is a conventional device which is configured tocrush the pieces of ore brought to it into pieces not to exceed thepredetermined maximum size, e.g., 150 mm, whereupon those pieces aredropped onto the conveyor 122 to be carried to the surge bin 124. Thesurge bin 124 is a conventional unit which includes a level sensor andis configured to provide the ore from it at a controlled rate to theconveyor 28 of the Analysis And Selection Station 104 so that there is aconstant fill factor of ore, e.g., approximately 20%-30% by weight, onthe conveyor 28 to ensure that the MR analyzer 32 works efficiently.

The ore deposited on the conveyor 28 is processed as described abovewith respect to system 20, with the metal-bearing ore upon which theAnalysis And Selection Station 102 operates being referred to as the“processing ore”, and with the metal-bearing ore diverted from the firstconveyor 28 to the second conveyors 50 and 52 by the diverter 38 beingreferred to as the “selected processing ore”. The selected processingore exiting the second conveyor 52 is provided as the input to theProduct Output Station 106.

The ore directed to the waste path by the diverter 38 is provided to theWaste Output Station 108. That station is best seen in FIG. 9 andbasically comprises a surge bin 142, a conveyor 144, a waste ore crusher146, and a conveyor 148. The surge bin 142 includes a level sensor. Thesurge bin is configured to receive the pieces of ore directed to thewaste path by the diverter 38, from whence those pieces of ore aredropped onto the conveyor and conveyed to the waste ore crusher 146. Thewaste ore crusher is also a conventional unit and serves to crush theore delivered to it into smaller pieces, which do not exceed apredetermined maximum size, e.g., 50 mm. Those pieces serve as a goodaggregate for roadbeds and other similar uses. Thus, the pieces of wasteore (the aggregate) which exit the waste ore crusher 146 are depositedon the conveyor 148. The pieces of ore are carried by that conveyor tothe exit end thereof, from whence they drop into a bin 42. The pieces ofaggregate deposited into the bin by the conveyor can be dispensed fromthe bin when desired to be loaded into the bed of a dump truck 44 fortransportation to some other site for subsequent use, e.g., for use asan aggregate roadbed.

The following are some commercially available components that can beused for an implementation of the exemplary sorting system 20 describedabove.

-   -   Magnet 24—Eriez Manufacturing Company (USA)    -   Magnetic Resonance Analyzers 32B and 55B—NextOre Pty Ltd,        Australia    -   Belt weightometers 32A and 54A (including belt speed measurement        device and calibration check weights and calibrating        mechanism)—Siemens Milltronics (Germany/USA), Thermo Scientific        Ramsey (USA), and Thayer Scale, Hyer Industries, Inc. (USA)    -   Diverter 38 (including hydraulic actuator and pumping system and        controls)—Vortex Global Inc. (USA)    -   Belt scraper 28C—Martin Engineering (USA)    -   Grizzly screen 118—Aury (Tianjin) Industrial Technology Co. Ltd.        (China)    -   Primary ore crusher 120—Sandvik Mining & Rock Technology        (Sweden)    -   Secondary ore crusher 126—Metso Corporation (Finland)    -   Single deck sizing screen 130—Aury (Tianjin) Industrial        Technology Co. Ltd. (China)    -   Tertiary ore crusher 136—Metso Corporation (Finland)

It should be pointed out at this juncture that the sorting systems asdescribed above are merely two exemplary embodiments of various sortingsystems that can be constructed in accordance with this invention. Thus,for sorting copper-bearing ore the particular system components andtheir arrangement can be chosen as desired, providing that the systemincludes two magnetic resonance analyzer units and any type of diverter,wherein a first magnetic resonance analyzer unit controls the diverterto divert input copper-bearing ore to a product line when predeterminedsorting criteria, e.g., a cut-off average percent value for a firstpredetermined length interval of time, is met, and a second magneticresonance analyzer unit to measure the actual average percent content ofthe ore over a second predetermined length interval of time in theproduct line to dynamically adjust the sorting criteria to result in aproduct ore having a desired average percentage by weight of copper asmeasured over a second predetermined length interval of time.Furthermore, while it is preferred that the system include the oresizing station, the product output station and the waste output station,any or all of such stations can be omitted if desired. Moreover, if anyor all of such stations are included in the system, they need not beconstructed and arranged as specifically disclosed above. Thus,alternative stations can be provided for sizing the ore from the mine toan acceptable size for processing by the system of this invention. Sotoo, alternative stations can be provided for sizing the output ore fromthe system. If sizing of the waste material is desired, alternativestations for effecting that end can be provided. Further still, asstated earlier the subject invention is not limited to sortingcopper-bearing ore, but can be used to sort other metal bearing ore thatcan be analyzed by magnetic resonance.

Without further elaboration the foregoing will so fully illustrate ourinvention that others may, by applying current or future knowledge,adopt the same for use under various conditions of service.

1.-6. (canceled)
 7. A system for producing pieces of a productmetal-bearing ore by processing pieces of an input metal-bearing ore,the input metal-bearing ore having a metal therein, the productmetal-bearing ore having a desired target average percentage by weightof the metal therein, said system comprising: a first conveyorconfigured to receive the input metal-bearing ore; a second conveyorconfigured to carry pieces of the product metal-bearing ore forcollection after said system has processed the input metal-bearing ore;a first magnetic resonance analyzing unit and an associated controllerconfigured for measuring the percentage by weight of the metal in theinput metal-bearing ore on said first conveyor at successive points intime, calculating the average percentage by weight of the metal in theinput metal-bearing ore on said first conveyor measured over firstpredetermined length intervals of time, establishing a cut-off value ofthe average percentage by weight of the metal in the input metal-bearingore on said first conveyor for producing the product metal-bearing ore,producing select signals when the average percentage by weight of themetal in the input metal-bearing ore on the first conveyor is equal toor greater than said cut-off value, generating an estimate of theaverage percentage by weight of the metal in the product metal-bearingore, and dynamically adjusting said cut-off value up or down to anadjusted value to produce said select signals if the average percentageby weight of the metal in the input metal-bearing ore on said firstconveyor is below or above the estimate of the average percentage byweight of the metal in the input metal-bearing ore on said firstconveyor; a diverter configured for receiving the input metal-bearingore from said first conveyor and directing the input metal-bearing oreon said first conveyor to a collection path in response to said selectsignals when the average percent by weight of the metal in the inputmetal-bearing ore on said first conveyor is equal to or greater thansaid adjusted value and directing the input metal-bearing ore on saidfirst conveyor to a waste path when the average percent by weight of themetal in the input metal-bearing ore on said first conveyor is less thansaid adjusted value; a second magnetic resonance analyzing unitconfigured for measuring the percentage by weight of the metal in theproduct metal-bearing ore on said second conveyor and for providing tosaid controller signals to fine tune said adjusted value up or down to atuned adjusted value to produce said select signals if the averagepercentage by weight of the metal in the product metal-bearing ore onsaid second conveyor is below or above the desired target averagepercentage by weight of the metal in the product metal-bearing ore,thereby causing said diverter to direct the input metal-bearing ore onsaid first conveyor to said collection path when the average percent byweight of the metal in the input metal-bearing ore on said firstconveyor is equal to or greater than said tuned adjusted value and todirect of the input metal-bearing ore on said first conveyor to saidwaste path when the average percent by weight of the metal in the inputmetal-bearing ore on said first conveyor is less than said tunedadjusted value; and an ore crusher to reduce the size of the pieces ofthe product metal-bearing ore so that they are no greater than apredetermined maximum size.
 8. A system for producing pieces of aproduct metal-bearing ore by processing pieces of an input metal-bearingore, the input metal-bearing ore having a metal therein, the productmetal-bearing ore having a desired target average percentage by weightof the metal therein, said system comprising: a first conveyorconfigured to receive the input metal-bearing ore; a second conveyorconfigured to carry pieces of the product metal-bearing ore forcollection after said system has processed the input metal-bearing ore;a first magnetic resonance analyzing unit and an associated controllerconfigured for measuring the percentage by weight of the metal in theinput metal-bearing ore on said first conveyor at successive points intime, calculating the average percentage by weight of the metal in theinput metal-bearing ore on said first conveyor measured over firstpredetermined length intervals of time, establishing a cut-off value ofthe average percentage by weight of the metal in the input metal-bearingore on said first conveyor for producing the product metal-bearing ore,producing select signals when the average percentage by weight of themetal in the input metal-bearing ore on the first conveyor is equal toor greater than said cut-off value, generating an estimate of theaverage percentage by weight of the metal in the product metal-bearingore, and dynamically adjusting said cut-off value up or down to anadjusted value to produce said select signals if the average percentageby weight of the metal in the input metal-bearing ore on said firstconveyor is below or above the estimate of the average percentage byweight of the metal in the input metal-bearing ore on said firstconveyor; a diverter configured for receiving the input metal-bearingore from said first conveyor and directing the input metal-bearing oreon said first conveyor to a collection path in response to said selectsignals when the average percent by weight of the metal in the inputmetal-bearing ore on said first conveyor is equal to or greater thansaid adjusted value and directing the input metal-bearing ore on saidfirst conveyor to a waste path when the average percent by weight of themetal in the input metal-bearing ore on said first conveyor is less thansaid adjusted value; a second magnetic resonance analyzing unitconfigured for measuring the percentage by weight of the metal in theproduct metal-bearing ore on said second conveyor and for providing tosaid controller signals to fine tune said adjusted value up or down to atuned adjusted value to produce said select signals if the averagepercentage by weight of the metal in the product metal-bearing ore onsaid second conveyor is below or above the desired target averagepercentage by weight of the metal in the product metal-bearing ore,thereby causing said diverter to direct the input metal-bearing ore onsaid first conveyor to said collection path when the average percent byweight of the metal in the input metal-bearing ore on said firstconveyor is equal to or greater than said tuned adjusted value and todirect of the input metal-bearing ore on said first conveyor to saidwaste path when the average percent by weight of the metal in the inputmetal-bearing ore on said first conveyor is less than said tunedadjusted value; and wherein said first conveyor, said first magneticresonance analyzing unit, said controller, and said diverter form ananalysis and selection station, and wherein said system additionallycomprises: an input sizing station comprising a first sizing screen anda first ore crusher, said first sizing screen being configured forreceiving the pieces of the input metal-bearing ore and for passingthose pieces that are no greater than a first predetermined maximum sizetherethrough to provide processing ore, said first ore crusher beingconfigured to receive pieces of the input metal-bearing ore from saidfirst sizing screen that are greater than said first predeterminedmaximum size for crushing those pieces to produce the processing ore andproviding the processing ore to said first conveyor of said analysis andselection station, the input metal-bearing ore that is diverted fromsaid first conveyor to said collection path being selected processingore; and a product output station forming a portion of said collectionpath for producing said product metal-bearing ore, said product outputstation comprises a second ore crusher, a second sizing screen and athird ore crusher, said second ore crusher being configured to receivethe selected processing ore to reduce the size of the pieces thereof toproduce a reduced size selected processing ore, said second sizingscreen being configured for receiving the reduced size selectedprocessing ore and for passing pieces thereof which are no greater thana second predetermined maximum size therethrough to said second conveyoras said product metal-bearing ore, said second predetermined maximumsize being less than said first predetermined maximum size, said thirdore crusher being configured to receive pieces of the reduced sizeselected processing ore greater than said second predetermined maximumsize from said second sizing screen for crushing said pieces of thereduced size selected processing ore to produce crushed pieces andproviding the crushed pieces back to said second sizing screen.
 9. Thesystem of claim 8, wherein said input sizing station also comprises apreliminary sizing screen and a preliminary ore crusher, saidpreliminary sizing screen being configured for providing pieces of theinput metal-bearing ore that are no greater than a third predeterminedmaximum size to said first sizing screen, said third predeterminedmaximum size being greater than said first predetermined maximum size,said preliminary sizing screen providing pieces of the inputmetal-bearing ore which are greater than said third predeterminedmaximum size to said preliminary ore crusher, said preliminary orecrusher being configured to crush the pieces of the input metal-bearingore from said preliminary sizing screen that are greater than said thirdpredetermined maximum size to a crushed size ore which can be providedback to said preliminary sizing screen.
 10. The system of claim 9,wherein the input metal-bearing ore comprises copper-bearing ore, andwherein said first predetermined maximum size is approximately 150 mm,said second predetermined maximum size is approximately 10 mm, and saidthird predetermined maximum size is approximately 450 mm.
 11. The systemof claim 8, wherein said input sizing station additionally comprises anapron feeder located between said preliminary sizing screen and saidfirst sizing screen, said apron feeder controlling the rate at which theinput metal-bearing ore whose pieces are no greater than said thirdpredetermined maximum size are provided to said first sizing screenunder the control of a first weighing device, said first weighing devicebeing located adjacent said first conveyor and said first magneticresonance analyzing unit.
 12. The system of claim 8 wherein said firstmagnetic resonance analyzing unit includes a coil having an internalcross sectional area, and wherein said input sizing station additionallycomprises a surge bin configured for receiving the input metal-bearingore that is no greater than said first predetermined size and forproviding such ore to said first conveyor at a controlled rate, saidcontrolled rate resulting in the amount of input metal-bearing ore onsaid first conveyor being maintained at approximately 20-30% of theinternal cross-sectional area of said coil of said first magneticresonance analyzing unit.
 13. The system of claim 8, wherein said secondconveyor and said second analyzer form a portion of said product outputstation.
 14. The system of claim 13, wherein said second magneticresonance analyzing unit includes a coil having an internal crosssectional area, and wherein said output sizing station additionallycomprises a surge bin configured for receiving the selected processingore from said analysis and selection station, said selected processingore being processed in said output sizing station to ensure the size ofpieces of said selected processing ore do not exceed a predeterminedmaximum size to produce said product metal-bearing ore and for providingsaid product metal-bearing ore to said second conveyor at a controlledrate, said controlled rate resulting in the amount of productmetal-bearing ore on said second conveyor being maintained atapproximately 20-30% of the internal cross-sectional area of said coilof said second first magnetic resonance analyzing unit.
 15. The systemof claim 8, additionally comprising a waste output station forming aportion of said waste path, wherein said waste output station comprisesa waste ore crusher configured to crush the input metal-bearing in saidwaste path into waste ore pieces having a maximum predetermined size.16. The system of claim 15, wherein said maximum predetermined size ofthe waste ore pieces is approximately 50 mm. 17.-20. (canceled)
 21. Amethod for producing pieces of a product metal-bearing ore by processingpieces of an input metal-bearing ore, the input metal-bearing ore havinga metal therein, the product metal-bearing ore having a desired targetaverage percentage by weight of the metal therein, the methodcomprising: providing the metal-bearing ore on a first conveyor;measuring the percentage by weight of the metal in the inputmetal-bearing ore on the first conveyor at successive points in time;calculating the average percentage by weight of the metal in the inputmetal-bearing ore on the first conveyor measured over firstpredetermined length intervals of time; establishing a cut-off value ofthe average percentage by weight of the metal in the input metal-bearingore on the first conveyor for producing the product metal-bearing ore;producing select signals when the average percentage by weight of themetal in the input metal-bearing ore on the first conveyor is equal toor greater than the cut-off value; generating an estimate of the averagepercentage by weight of the metal in the product metal-bearing ore;dynamically adjusting the cut-off value up or down to an adjusted valueto produce the select signals if the average percentage by weight of themetal in the input metal-bearing ore on the first conveyor is below orabove the estimate of the average percentage by weight of the metal inthe input metal-bearing ore on the first conveyor; directing the inputmetal-bearing ore on the first conveyor to a collection path in responseto the select signals when the average percent by weight of the metal inthe input metal-bearing ore on the first conveyor is equal to or greaterthan the adjusted value; directing the input metal-bearing ore on thefirst conveyor to a waste path when the average percent by weight of themetal in the input metal-bearing ore on the first conveyor is less thanthe adjusted value; measuring the percentage by weight of the metal inthe product metal-bearing ore on a second conveyor and fine tuning theadjusted value up or down to a tuned adjusted value to produce theselect signals if the average percentage by weight of the metal in theproduct metal-bearing ore on the second conveyor is below or above thedesired target average percentage by weight of the metal in the productmetal-bearing ore, whereupon the input metal-bearing ore on the firstconveyor is directed to the collection path when the average percent byweight of the metal in the input metal-bearing ore on the first conveyoris equal to or greater than the tuned adjusted value and the inputmetal-bearing ore on the first conveyor is directed to the waste pathwhen the average percent by weight of the metal in the inputmetal-bearing ore on the first conveyor is less than the tuned adjustedvalue; preliminarily sizing the pieces of the input metal-bearing ore sothat the pieces thereof are no greater than a first predeterminedmaximum size and providing those pieces to the first conveyor; sizingthe pieces of the input metal-bearing ore provided to the collectionpath so that the pieces thereof are no greater than a secondpredetermined maximum size, the second predetermined size being lessthan the first predetermined maximum size; and providing the pieces ofthe input metal-bearing ore that are no greater than the secondpredetermined maximum size to the second conveyor.
 22. The method ofclaim 21 wherein the preliminary sizing of the pieces of the inputmetal-bearing ore comprises: screening pieces of the input metal-bearingore whereupon pieces of that ore which are no greater than a thirdpredetermined maximum size are introduced to the first conveyor, thethird predetermined maximum size being greater than the firstpredetermined maximum size; and reducing the size of the pieces of theinput metal-bearing ore that are greater than the third predeterminedmaximum size to a size which is no greater than the third predeterminedmaximum size for introduction to the first conveyor.
 23. The method ofclaim 22, wherein the metal-bearing ore comprises copper-bearing ore,the metal is copper, the first predetermined maximum size isapproximately 150 mm, the second predetermined maximum size isapproximately 10 mm, and the third predetermined maximum size isapproximately 450 mm.
 24. The method of claim 22, wherein the methodadditionally comprises controlling a rate at which the pieces of theinput metal-bearing ore which are no greater than the thirdpredetermined maximum size are screened.
 25. A method for producingpieces of a product metal-bearing ore by processing pieces of an inputmetal-bearing ore, the input metal-bearing ore having a metal therein,the product metal-bearing ore having a desired target average percentageby weight of the metal therein, the method comprising: providing themetal-bearing ore on a first conveyor; measuring the percentage byweight of the metal in the input metal-bearing ore on the first conveyorat successive points in time; calculating the average percentage byweight of the metal in the input metal-bearing ore on the first conveyormeasured over first predetermined length intervals of time; establishinga cut-off value of the average percentage by weight of the metal in theinput metal-bearing ore on the first conveyor for producing the productmetal-bearing ore; producing select signals when the average percentageby weight of the metal in the input metal-bearing ore on the firstconveyor is equal to or greater than the cut-off value; generating anestimate of the average percentage by weight of the metal in the productmetal-bearing ore; dynamically adjusting the cut-off value up or down toan adjusted value to produce the select signals if the averagepercentage by weight of the metal in the input metal-bearing ore on thefirst conveyor is below or above the estimate of the average percentageby weight of the metal in the input metal-bearing ore on the firstconveyor; directing the input metal-bearing ore on the first conveyor toa collection path in response to the select signals when the averagepercent by weight of the metal in the input metal-bearing ore on thefirst conveyor is equal to or greater than the adjusted value; directingthe input metal-bearing ore on the first conveyor to a waste path whenthe average percent by weight of the metal in the input metal-bearingore on the first conveyor is less than the adjusted value; measuring thepercentage by weight of the metal in the product metal-bearing ore on asecond conveyor and fine tuning the adjusted value up or down to a tunedadjusted value to produce the select signals if the average percentageby weight of the metal in the product metal-bearing ore on the secondconveyor is below or above the desired target average percentage byweight of the metal in the product metal-bearing ore, whereupon theinput metal-bearing ore on the first conveyor is directed to thecollection path when the average percent by weight of the metal in theinput metal-bearing ore on the first conveyor is equal to or greaterthan the tuned adjusted value and the input metal-bearing ore on thefirst conveyor is directed to the waste path when the average percent byweight of the metal in the input metal-bearing ore on the first conveyoris less than the tuned adjusted value; and providing a first magneticresonance analyzing unit which includes a coil having an internal crosssectional area, and wherein the method additionally comprises: providingthe pieces of the input metal-bearing ore that are no greater than thefirst predetermined size to said first conveyor at a controlled rate sothat the amount of the input metal-bearing ore on said first conveyor ismaintained at approximately 20-30% of the internal cross sectional areaof said first magnetic resonance analyzing unit.
 26. The method of claim25 wherein said further comprising providing a second magnetic resonanceanalyzing unit which includes a coil having an internal cross sectionalarea, and wherein the method additionally comprises: providing thepieces of the product metal-bearing ore that are no greater than thesecond predetermined size on said second conveyor at a controlled rateso that the amount of the product metal-bearing ore on said secondconveyor is maintained at approximately 20-30% of the internal crosssectional area of said second magnetic resonance analyzing unit.
 27. Themethod of claim 26 wherein said second magnetic resonance analyzing unitincludes a coil having an internal cross sectional area, and wherein themethod additionally comprises: providing the pieces of the productmetal-bearing ore that are no greater than the second predetermined sizeon said second conveyor at a controlled rate so that the amount of theproduct metal-bearing ore on said second conveyor is maintained atapproximately 20-30% of the internal cross sectional area of said secondmagnetic resonance analyzing unit.
 28. The method of claim 22,additionally comprising sizing the pieces of the input metal-bearing orein the waste path so that the pieces thereof are no greater than afourth predetermined maximum size.
 29. The method of claim 28, whereinthe fourth maximum predetermined size is approximately 50 mm.